Yamaha FJ1100 & FJ1200 Motorcycle Service Repair Manual 1984-1993
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🏷️ Basic Information Identification Make: Yamaha Model: FJ1100 / FJ1200 Model Family: FJ Motorcycle Type: Sport Touring Generation Generation Code: First Generation (FJ1100/FJ1200) Codes Engine Code Primary: 47E (FJ1100), 3CV, 3XW, 4BS (FJ1200) 👋 Introduction Market Position Target Audience: Do-it-yourself enthusiasts and experienced mechanics seeking comprehensive repair and maintenance guidance. Competitive Analysis Value Proposition: An inexpensive way to keep your motorcycle working properly, empowering owners to perform their own repairs and save money. Key Features Instructional Method: Step-by-step instructions based on complete disassembly, guided by hundreds of photos and illustrations. 📋 Manual Details Coverage Areas Production Model Years Covered: 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993 Page Count Total Pages: 459 Manual Type Manual Classification: Complete Service Repair Manual Language Language Of Manual: English Format File Format: PDF Features Download Format Options: Digital Download (PDF), suitable for saving to hard-drive or burning to CD-ROM. 📖 Manual Coverage Systems Covered Engine System Coverage: Complete Engine Overhaul, including disassembly, assembly, component inspection, and torque specifications. Cooling System Coverage: Detailed coverage of the liquid-cooled system, including radiator, thermostat, water pump, and coolant specifications. Fuel System Coverage: Comprehensive carburetor section covering tuning, cleaning, rebuilding, and synchronization. Chassis System Coverage: Includes frame, suspension (front forks and rear monoshock), steering, wheels, and brakes. Electrical System Coverage: Extensive coverage including wiring diagrams, lighting, ignition system, charging system, starter, and instruments. Procedures Included Maintenance Procedures: Periodic inspection and adjustment, lubrication, filter changes, fluid checks, and general upkeep. Repair Procedures: Detailed step-by-step instructions for a complete tear-down and rebuild of all major motorcycle components. Troubleshooting Procedures: Diagnostic procedures and common issue identification for the engine, electrical system, and chassis. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures for identifying and resolving mechanical and electrical faults. Rebuild Scope: Full rebuild instructions from complete disassembly to reassembly, suitable for novice to expert mechanics. Documentation Type: Includes detailed illustrations, diagrams, wiring schematics, and specifications. 📊 Manual Specifications File Format PDF Reader Requirement: Adobe PDF Reader Compatibility: All Versions of Windows & Mac, Linux OS, iPhone, iPad, Android devices. Print Quality Page Integrity: 100% Complete and Intact, no missing/corrupt pages or sections. Binding Type Digital Delivery Method: Instant Download Paper Type Printable Format: Can be zoomed and printed. Searchability Navigational Features: Bookmarked and Searchable for easy navigation and quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve per cylinder, V-Four Performance Displacement Fj1100: 1097 cc Displacement Fj1200: 1188 cc Bore X Stroke Fj1100: 74.0 mm x 64.0 mm Bore X Stroke Fj1200: 77.0 mm x 63.8 mm Compression Ratio Fj1100: 9.5:1 Compression Ratio Fj1200: 9.7:1 (early), 10.0:1 (later) Horsepower Approx Fj1100: 120-130 hp @ 8500 rpm (claimed) Horsepower Approx Fj1200: 125-135 hp @ 8500 rpm (claimed) Torque Approx Fj1100: 96 Nm @ 7500 rpm (claimed) Torque Approx Fj1200: 103 Nm @ 7000 rpm (claimed) Fuel System Carburetor Type: Constant Velocity (CV) carburetors Carburetor Size Fj1100: 34 mm Mikuni BS Carburetor Size Fj1200: 36 mm Mikuni BS 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Features Clutch Type: Wet, multiple-disc, cable-actuated 📐 Dimensions Weights Dry Weight Fj1100: Approximately 233 kg (514 lbs) Dry Weight Fj1200: Approximately 245 kg (540 lbs) Fuel Capacity: 24 Liters (6.3 US gallons) 🛡️ Safety Features Active Features Braking System Front: Dual 270mm disc brakes with hydraulic calipers Braking System Rear: Single 270mm disc brake with hydraulic caliper Passive Features Frame Type: Steel, double-cradle frame 💡 Technology Features Infotainment Instrumentation: Analog speedometer, tachometer, fuel gauge, temperature gauge, and warning lights. Driver Assistance ABS Availability: ABS was optional on some later FJ1200 models. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time intervals; typically every 4,000-6,000 km (2,500-3,700 miles). Valve Clearance Check: Refer to manual for specific mileage intervals; critical for V-Four engine performance and longevity. Fluid Specifications Engine Oil Type: Yamaha recommends Yamalube or equivalent API SG, JASO MA certified 10W-40 or 20W-50 (refer to manual for seasonal variations). Coolant Type: Permanent type anti-freeze coolant (ethylene glycol based) mixed with distilled water at a 50:50 ratio. Brake Fluid Type: DOT 3 or DOT 4 hydraulic brake fluid. Known Issues Common Wear Items: Cam chain tensioner (can become noisy), electrical connector corrosion, suspension seals (forks and shock). Carburetor Maintenance: Regular cleaning and synchronization of carburetors is essential for smooth running due to their complexity. 📚 Vehicle History Brand Heritage Manufacturer Origin: Japan Model Evolution Fj1100 Introduction: Introduced in 1984 as Yamaha's flagship sport-touring motorcycle, offering a blend of performance and long-distance comfort. Fj1200 Introduction: Launched in 1986 as an evolution of the FJ1100, featuring increased displacement and numerous refinements. Key Advancements: The FJ series was known for its sophisticated V-Four engine, advanced (for its time) suspension, and comfortable ergonomics. Production Production Period: 1984-1993 🏆 Awards & Recognition Recognitions Industry Acclaim: Widely praised at its release for its performance, comfort, and...
Digital Download (PDF), suitable for saving to hard-drive or burning to CD-ROM.
📖 Manual Coverage
Systems Covered
Engine System Coverage:
Complete Engine Overhaul, including disassembly, assembly, component inspection, and torque specifications.
Cooling System Coverage:
Detailed coverage of the liquid-cooled system, including radiator, thermostat, water pump, and coolant specifications.
Fuel System Coverage:
Comprehensive carburetor section covering tuning, cleaning, rebuilding, and synchronization.
Chassis System Coverage:
Includes frame, suspension (front forks and rear monoshock), steering, wheels, and brakes.
Electrical System Coverage:
Extensive coverage including wiring diagrams, lighting, ignition system, charging system, starter, and instruments.
Procedures Included
Maintenance Procedures:
Periodic inspection and adjustment, lubrication, filter changes, fluid checks, and general upkeep.
Repair Procedures:
Detailed step-by-step instructions for a complete tear-down and rebuild of all major motorcycle components.
Troubleshooting Procedures:
Diagnostic procedures and common issue identification for the engine, electrical system, and chassis.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostic procedures for identifying and resolving mechanical and electrical faults.
Rebuild Scope:
Full rebuild instructions from complete disassembly to reassembly, suitable for novice to expert mechanics.
Documentation Type:
Includes detailed illustrations, diagrams, wiring schematics, and specifications.
📊 Manual Specifications
File Format
PDF Reader Requirement:
Adobe PDF Reader
Compatibility:
All Versions of Windows & Mac, Linux OS, iPhone, iPad, Android devices.
Print Quality
Page Integrity:
100% Complete and Intact, no missing/corrupt pages or sections.
Binding Type
Digital Delivery Method:
Instant Download
Paper Type
Printable Format:
Can be zoomed and printed.
Searchability
Navigational Features:
Bookmarked and Searchable for easy navigation and quick information retrieval.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 4-valve per cylinder, V-Four
Performance
Displacement Fj1100:
1097 cc
Displacement Fj1200:
1188 cc
Bore X Stroke Fj1100:
74.0 mm x 64.0 mm
Bore X Stroke Fj1200:
77.0 mm x 63.8 mm
Compression Ratio Fj1100:
9.5:1
Compression Ratio Fj1200:
9.7:1 (early), 10.0:1 (later)
Horsepower Approx Fj1100:
120-130 hp @ 8500 rpm (claimed)
Horsepower Approx Fj1200:
125-135 hp @ 8500 rpm (claimed)
Torque Approx Fj1100:
96 Nm @ 7500 rpm (claimed)
Torque Approx Fj1200:
103 Nm @ 7000 rpm (claimed)
Fuel System
Carburetor Type:
Constant Velocity (CV) carburetors
Carburetor Size Fj1100:
34 mm Mikuni BS
Carburetor Size Fj1200:
36 mm Mikuni BS
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Features
Clutch Type:
Wet, multiple-disc, cable-actuated
📐 Dimensions
Weights
Dry Weight Fj1100:
Approximately 233 kg (514 lbs)
Dry Weight Fj1200:
Approximately 245 kg (540 lbs)
Fuel Capacity:
24 Liters (6.3 US gallons)
🛡️ Safety Features
Active Features
Braking System Front:
Dual 270mm disc brakes with hydraulic calipers
Braking System Rear:
Single 270mm disc brake with hydraulic caliper
Passive Features
Frame Type:
Steel, double-cradle frame
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer, tachometer, fuel gauge, temperature gauge, and warning lights.
Driver Assistance
ABS Availability:
ABS was optional on some later FJ1200 models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time intervals; typically every 4,000-6,000 km (2,500-3,700 miles).
Valve Clearance Check:
Refer to manual for specific mileage intervals; critical for V-Four engine performance and longevity.
Fluid Specifications
Engine Oil Type:
Yamaha recommends Yamalube or equivalent API SG, JASO MA certified 10W-40 or 20W-50 (refer to manual for seasonal variations).
Coolant Type:
Permanent type anti-freeze coolant (ethylene glycol based) mixed with distilled water at a 50:50 ratio.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Common Wear Items:
Cam chain tensioner (can become noisy), electrical connector corrosion, suspension seals (forks and shock).
Carburetor Maintenance:
Regular cleaning and synchronization of carburetors is essential for smooth running due to their complexity.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Japan
Model Evolution
Fj1100 Introduction:
Introduced in 1984 as Yamaha's flagship sport-touring motorcycle, offering a blend of performance and long-distance comfort.
Fj1200 Introduction:
Launched in 1986 as an evolution of the FJ1100, featuring increased displacement and numerous refinements.
Key Advancements:
The FJ series was known for its sophisticated V-Four engine, advanced (for its time) suspension, and comfortable ergonomics.
Production
Production Period:
1984-1993
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Widely praised at its release for its performance, comfort, and innovative V-Four engine, establishing Yamaha as a major player in the sport-touring segment.
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